US8232786B2 - Fast transient step load response in a power converter - Google Patents

Fast transient step load response in a power converter Download PDF

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US8232786B2
US8232786B2 US12/236,798 US23679808A US8232786B2 US 8232786 B2 US8232786 B2 US 8232786B2 US 23679808 A US23679808 A US 23679808A US 8232786 B2 US8232786 B2 US 8232786B2
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Prior art keywords
power converter
load current
duty cycle
voltage
switching device
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US20090085546A1 (en
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Vijay G. Phadke
Arlaindo V. Asuncion
Evan M. Espina
Yancy F. Boncato
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Aes Global Holdings Pte Ltd
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Astec International Ltd
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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/42—Circuits or arrangements for compensating for or adjusting power factor in converters or inverters
    • H02M1/4208—Arrangements for improving power factor of AC input
    • H02M1/4225—Arrangements for improving power factor of AC input using a non-isolated boost converter
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M3/00—Conversion of DC power input into DC power output
    • H02M3/02—Conversion of DC power input into DC power output without intermediate conversion into AC
    • H02M3/04—Conversion of DC power input into DC power output without intermediate conversion into AC by static converters
    • H02M3/10—Conversion of DC power input into DC power output without intermediate conversion into AC by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M3/145—Conversion of DC power input into DC power output without intermediate conversion into AC by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M3/155—Conversion of DC power input into DC power output without intermediate conversion into AC by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only
    • H02M3/156—Conversion of DC power input into DC power output without intermediate conversion into AC by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators
    • H02M3/157—Conversion of DC power input into DC power output without intermediate conversion into AC by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators with digital control
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B70/00—Technologies for an efficient end-user side electric power management and consumption
    • Y02B70/10—Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes

Definitions

  • the present disclosure relates to power converters.
  • a typical PFC boost rail for regulating a voltage of 390 volts often requires a 450 volt bulk capacitor because the voltage over shoot during a load dump could be as high as 430 volts.
  • VRM voltage regulator module
  • a method of controlling a power converter having at least one switching device for supplying an output voltage and a load current to a load includes sensing the output voltage, sensing the load current.
  • the method also includes controlling a duty cycle of the switching device according to the sensed output voltage and a voltage control loop when a rate of change of the load current does not exceed a threshold level.
  • the method further includes adjusting the duty cycle of the switching device set by the voltage control loop when the rate of change of the load current exceeds the threshold level.
  • a power converter includes a controller and at least one switching device.
  • the controller is configured to control a duty cycle of the switching device according to a sensed output voltage and a voltage control loop when a rate of change of a load current does not exceed a threshold level.
  • the controller is also configured to adjust the duty cycle of the switching device set by the voltage control loop when the rate of change of the load current exceeds the threshold level.
  • FIG. 1 is a circuit diagram of a power converter according to one embodiment including a PFC boost converter, a switching power supply, a controller and a sampling circuit.
  • FIG. 2 is a circuit diagram of a voltage regulator module (VRM) system according to another embodiment of the present disclosure.
  • VRM voltage regulator module
  • FIG. 3 is a circuit diagram of an example analog implementation of a power converter including an analog circuit for adjusting the duty cycle of the power converter in response to a step load change.
  • FIG. 4 is a graph of the current and voltage effects of a step increase in load on the power converter in FIG. 3 without load current sensing.
  • FIG. 5 is a graph of the current and voltage effects of a step increase in load on the power converter in FIG. 3 with load current sensing and proportional current control.
  • FIG. 6 is a graph of the current and voltage effects of a step decrease in load on the power converter in FIG. 3 without load current sensing.
  • FIG. 7 is a graph of the current and voltage effects of a step decrease in load on the power converter in FIG. 3 with load current sensing and proportional current control.
  • Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
  • first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
  • a method of controlling a power converter having at least one switching device for supplying an output voltage and a load current to a load includes sensing the output voltage and sensing the load current.
  • the method also includes controlling a duty cycle of the switching device according to the sensed output voltage and a voltage control loop when a rate of change of the load current does not exceed a threshold level.
  • the method further includes adjusting the duty cycle of the switching device set by the voltage control loop when the rate of change of the load current exceeds the threshold level.
  • the method can be used in any power converter topology having one or more switching devices where output current to a load can be sensed after the converter's bulk output capacitor.
  • the method may be used in a power factor correction (PFC) boost regulator, a voltage regulation module (VRM) and/or a DC-DC converter.
  • PFC power factor correction
  • VRM voltage regulation module
  • the method can, among other things, reduce voltage overshoot and undershoot.
  • Example power converters for performing according to the aforementioned method will now be discussed with reference to FIGS. 1-7 . It should be understood, however, that the method can be performed in a variety of other power converters without departing from the teachings of this disclosure.
  • FIG. 1 illustrates a power supply, generally indicated by the reference numeral 100 according to at least one aspect of the present disclosure.
  • the power supply includes a PFC boost power converter 102 for providing an output voltage, and current, to a load.
  • the load is a switching power converter 104 .
  • An AC voltage from a voltage source 106 is rectified by a bridge rectifier 108 and input to the PFC boost power converter 102 .
  • the PFC boost power converter 102 provides power factor correction and supplies an output voltage that is input to the switching power converter 104 .
  • the switching power converter 104 supplies power to a load 110 .
  • a controller 112 samples the voltage supplied by the PFC boost power converter 102 .
  • the controller 112 may be an analog or a digital controller.
  • the controller 112 controls, among other things, the switching duty cycle of switching devices, such as Q 1 , in the PFC boost power converter 102 in order to regulate the output voltage of the PFC boost power converter 102 .
  • a current in the power converter 102 is sampled at a second frequency. In some embodiments, the second frequency is greater than the first frequency at which the voltage is sampled. In FIG. 1 , the current is illustrated being sampled by a sampling circuit 114 .
  • the sampling circuit 114 may be a part of the controller 112 , external circuitry or a combination of the two.
  • the current is sensed using a series sense resistor 116 coupled to the converter 102 on the output side of a bulk output capacitor 118 .
  • Any other device capable of sensing the current such as a current transformer, Hall Effect sensor, etc., can also be used instead of, or along with, the sense resistor 116 .
  • the sampling circuit 114 can be a discrete circuit, part of the controller 112 , or a combination of the controller 112 and parts external to the controller 112 .
  • the sampling circuit 114 may comprise external comparators which generate a logic level input to the controller 112 to indicate the level of the load current.
  • the sampling circuit 114 may alternatively, or additionally, include comparators within the controller 112 (if available).
  • the sampling circuit may also, or additionally, include a fast Analog to Digital converter (ADC) in the controller 112 .
  • ADC Analog to Digital converter
  • the load current changes very quickly.
  • Each sample of the current is compared to the previous sample.
  • the sampling circuit 114 determines that the load is changing rapidly and that the duty cycle of the switching device Q 1 should be adjusted in order to minimize voltage overshoot and undershoot.
  • the maximum rate of current change that the PFC boost power converter 102 can provide is determined by, among other things, the duty cycle of the switching device Q 1 .
  • adjusting the duty cycle changes how quickly the PFC boost power converter 102 can respond to the changing load and thereby changes how much voltage overshoot or undershoot is generated.
  • the current is sampled at a frequency sufficient to detect changing current before the output voltage changes. This allows the controller 112 to respond quickly to the changing output current.
  • the sampling circuit 114 determines an adjustment to the duty cycle of the switching device. This can be accomplished numerous ways.
  • the sampling circuit 114 may include a predetermined lookup table that has been calibrated to provide a desired duty cycle adjustment based on one or more operating parameters such as input conditions, output voltage, output current and rate of change of output current.
  • the adjustment to the duty cycle may also be determined by equation.
  • the sampling circuit 114 overrides the duty cycle set by the voltage control loop of the controller 112 and adjusts the duty cycle according to the duty cycle adjustment previously determined. The duration of this adjustment can be set/determined in numerous ways.
  • the duration can, for example, be a set length of time, a number of switching cycles, or can last until a steady state is achieved. Whichever manner of determining the duration is used, voltage control of the duty cycle is taken over again by the controller 112 when the duration of the adjustment ends.
  • the adjusted duty cycle may be derived from two components.
  • the first component is the duty cycle provided by the controller 112 based on, for example, a reference and the output voltage level. When the power converter 102 is operating at steady state, this is the only component for derivation of the adjusted duty cycle.
  • the second component can be implemented by using the load current as an additional input to the controller 112 for calculating the duty cycle.
  • the second component for the adjusted duty cycle can be provided by a non-linear component.
  • the non-linear component will modify or replace the original duty cycle to achieve the adjusted duty cycle when the output current to the load changes rapidly.
  • the determination of the amount to be added to (or subtracted from) the original duty cycle may be based on an equation or a look-up table.
  • the equation or look-up table can be generated by simulation and then fine tuned by actual testing.
  • the power supply 100 is operating in steady state at 50% load and drawing 2 A of input current. If a step load is applied to the output of the power supply at a certain slew rate, it would result in a current slew rate on the input side that depends on the step-up or step-down ratio of the power supply. For example, if the load current steps from 50% to 100% at a rate that requires the input current to increase from 2 A to 4 A in 40 microseconds, it will result in a slew rate of 50 milliamps per microsecond.
  • the bulk capacitor 118 While the current is increasing, the extra 2 A of current required will be supplied by the bulk capacitor 118 . Because the bulk capacitor 118 is chosen to have a large capacitance, it does not discharge appreciably in this time. However, there will be a small drop in the voltage input to the switching power converter 104 due to the equivalent series resistance (ESR) of the capacitor 118 . Because the drop in voltage caused by the ESR of the capacitor is very small, the controller 112 may not recognize the change. Additionally, the controller 112 is sampling the voltage at a slow frequency. Thus, it will take some time before the controller 112 samples the voltage and recognizes that the voltage has changed. If the voltage is sampled at, for example 2 kHz, the voltage is only sampled once every 500 microseconds.
  • ESR equivalent series resistance
  • the sampling circuit 114 is sampling the current at a frequency greater than the voltage sampling frequency. The exact frequency depends upon the controller 112 , ADCs and/or other elements selected for the sampling circuit 114 , but a frequency of 100 kHz is a reasonable example. Therefore, the sampling circuit is sampling the current once every 10 microseconds and would acquire four samples during the 40 microseconds required for the current to reach 4 A.
  • each current sample is quite large as compared to the previous value.
  • the sampling circuit 114 will determine a new duty cycle for the switch Q 1 .
  • This sampling circuit 114 may determine the new duty cycle by retrieving the adjustment from a pre-calibrated look up table as discussed above.
  • the sampling circuit then overrides the voltage control portion of the controller 112 to change or augment the duty cycle to the new duty cycle for a pre-determined time.
  • This adjusted duty cycle can be as high as 100%.
  • the adjusted duty cycle will stay at this level for a certain duration as discussed above unless there is a substantial change in load current.
  • voltage control of the duty cycle is taken over again by the controller 112 when the duration of the adjustment ends.
  • the sample circuit 114 is operable to respond very quickly and decrease the duty cycle to help minimize voltage overshoot.
  • the duty cycle of Q 1 will be reduced for a certain duration as discussed above.
  • the reduced duty cycle can be as low as a 0% duty cycle.
  • the VRM 220 receives a DC input voltage and provides an output voltage to a load 210 .
  • the load is illustrated a microprocessor, but the load can be any load with which a VRM can be used.
  • a controller 212 samples the output voltage supplied by the VRM 220 at a first frequency and an output current is sampled at a second frequency.
  • the current is illustrated being sampled by a sampling circuit 214 .
  • the sampling circuit 214 may be a part of the controller 212 , external circuitry or a combination of the two.
  • the current is sensed using a series sense resistor 216 . Any other device capable of sensing the current, such as a current transformer, Hall Effect sensor, etc., can also be used instead of, or along with, the sense resistor 216 .
  • the VRM 220 operates on a 12V input to produce an output voltage of 1.2V and delivers maximum load current of 20 A. It operates at 1 MHz switching frequency and uses 0.2 uH output inductor and is placed close to its load. The load can change current at a rate of 100 A per microsecond. Specifications allow a maximum 50 mV overshoot and/or undershoot in the voltage provided to the load.
  • the ESR of output capacitor 218 is shown as resistor 222 .
  • the capacitor 218 is chosen such that its ESR is half the resistance of the sense resistor 216 .
  • the current sampling circuit 214 includes four comparator circuits configured to detect when load current changes in steps of 25% of the maximum possible change.
  • the current detection signal from the sense resistor 216 can also be amplified using a precision, low offset differential amplifier and fed to an Analog to Digital Converter (ADC) of the controller 212 for processing.
  • ADC Analog to Digital Converter
  • a typical fast comparator and fast controller 212 can perform this task in 50 to 75 nanoseconds.
  • the change in output current will occur in 150 nanoseconds.
  • the comparators recognize the change in current and trigger an interrupt signal.
  • the extra load current of 15 A is supplied by the capacitor 218 .
  • the capacitor would discharge by 7 mV. Because of the capacitor discharging, the voltage drop across the sense resistor 216 , and the voltage drop across the resistor 222 , the voltage provided to the load will decrease by approximately 22 mV.
  • the controller 212 changes the duty cycle to nearly 100% and current in the VRM inductor 224 will start to increase. The rate of increase in current will depend on the value of the inductor.
  • the current ramp rate in the inductor is predictable, and the modified duty cycle can be used for a predetermined length of time.
  • the duty cycle is increased to approximately 100% for only 277 nanoseconds when the load switches from 5 A to 20 A. After that time, the controller is allowed to resume voltage control of the duty cycle.
  • FIG. 3 illustrates an analog circuit 300 according to one or more aspects of the present disclosure for providing power to a load 310 .
  • the circuit 300 includes a power converter 326 providing an output voltage to the load 310 .
  • the circuit 300 includes a voltage error amplifier 328 for amplifying the error in the voltage supplied to the load 310 .
  • the circuit 300 further includes an integrated current sampling and control circuit 330 .
  • FIG. 4 graphically illustrates the effects of a step change in load on the output voltage of the power converter 326 of FIG. 3 if the current sampling and control circuit 330 is not used.
  • the power converter 326 is subjected to a step load change from 30 A to 60 A at a rate of 5 A per microsecond.
  • this step change can be seen in a change in the voltage across a series sense resistor R 4 in the power converter 326 .
  • the voltage output from the power converter 326 spikes down when the load changes suddenly.
  • the voltage has dropped from 12 volts to 11.4 volts.
  • the voltage increases until it overshoots the steady state 12 volts. This pattern continues until the current through the inductor and the output voltage reach a steady state again.
  • FIG. 5 illustrates the effects of the same step load change on the circuit 300 in FIG. 3 when the current sampling and control circuit 330 is used.
  • the power converter is subjected to the same 30 A to 60 A load change.
  • the minimum value of the output voltage is approximately 11.65 volts.
  • the voltage drop caused by the change in load is reduced by more than 0.2 volts as compared the results shown in FIG. 4 .
  • FIGS. 6 and 7 similarly illustrate the response of the power converter 326 to a step decrease in load.
  • the step change in the load is a decrease from 60 A to 30 A at a rate of 5 A per microsecond.
  • FIG. 6 illustrates the response when the current sampling and control circuit 330 is not used.
  • the load change is evident in the change in voltage across the sense resistor R 4 at 636 .
  • the voltage output from the power converter 326 spikes up from the steady state 12V output in response to the sudden change in load and peaks at 12.6V.
  • FIG. 7 the results of the power converter 326 being subjected to the same step decrease in load when the current sampling and control circuit 330 is used are shown in FIG. 7 .
  • FIG. 7 Like FIG.
  • the change in load can be seen in the voltage across the sense resistor R 4 at 736 .
  • the output voltage of the power converter 326 spikes up from the steady state 12V at 738 .
  • the output voltage peaks below 12.4 volts.
  • using the current sampling and control circuit 330 reduced the peak voltage overshoot by more than 0.2 volts.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Dc-Dc Converters (AREA)
US12/236,798 2007-09-28 2008-09-24 Fast transient step load response in a power converter Active 2029-08-05 US8232786B2 (en)

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US12/236,798 US8232786B2 (en) 2007-09-28 2008-09-24 Fast transient step load response in a power converter
EP08253146.8A EP2043242B1 (fr) 2007-09-28 2008-09-26 Convertisseur de puissance avec haute dynamique et PFC

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US12/236,798 US8232786B2 (en) 2007-09-28 2008-09-24 Fast transient step load response in a power converter

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EP2509201B1 (fr) * 2011-04-04 2016-03-30 Nxp B.V. Contrôleur pour alimentation électrique à découpage du type quasi-résonant
TWI443930B (zh) * 2011-09-23 2014-07-01 亞旭電子科技（江蘇）有限公司 充電電流控制方法及充電系統
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WO2013097824A1 (fr) 2011-12-31 2013-07-04 深圳市比亚迪汽车研发有限公司 Véhicule électrique et système d'alimentation et régulateur de moteur pour véhicule électrique
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JP6206162B2 (ja) * 2013-12-19 2017-10-04 富士通株式会社 Ａｃ／ｄｃコンバータおよびａｃ／ｄｃ変換方法
JP2016149903A (ja) * 2015-02-13 2016-08-18 トヨタ自動車株式会社 昇圧制御装置
CN106033936A (zh) * 2015-03-09 2016-10-19 光宝电子(广州)有限公司 具有旁路功能的电源供应器及其操作方法
AT15366U1 (de) * 2016-04-07 2017-07-15 Tridonic Gmbh & Co Kg Verfahren und Schaltungsanordnung zum Betrieb von Leuchtmitteln
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CN116846203A (zh) * 2023-01-12 2023-10-03 深圳威迈斯新能源股份有限公司 功率变换器逆变过流的防控方法以及保护装置

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